Conduits with Capillary Structures

ABSTRACT

The present disclosure provides a conduit (10). The conduit (10) includes (i) an annular wall (66) composed of a polymeric material, the annular wall (66) defining an annular passageway; (ii) a plurality of channels (68) extending along a length of an inner surface (62) of the annular wall (66); and (iii) a slip material located in the channels (68), the slip material forming a capillary structure (70) in the channels (68), and the capillary structures (70) protruding radially inward from the annular wall (66).

BACKGROUND

The present disclosure is directed to conduits having capillarystructures.

A longstanding problem in the cable installation process is the hightension that arises as cables are pulled into and through a conduit. Themain cause of high tension during installation is high coefficient offriction (COF) materials included in conduits and/or cable jackets.Attempts have been made to incorporate low COF materials into conduits,such as through a blending process. However, incorporation of low COFmaterials into conduits through a blending process has been found tocompromise the mechanical properties of the conduit. Further, thisprocess requires a high load of low COF materials, which are expensive.Attempts have also been made to coextrude low COF materials in the innersurface of a conduit. However, coextrusion of a layer of low COFmaterials typically requires a tie layer to create a bond between theconduit material and the coextruded low COF material. This process alsorequires a high load of low COF materials.

The art recognizes the need for a conduit that includes low COFmaterials, the conduit reduced tension during cable installation,without compromising the mechanical properties of the conduit. The artalso recognizes the need for a conduit that includes a small load of lowCOF materials such that the conduit is less expensive than thoseproduced via a blending process.

SUMMARY

The present disclosure provides a conduit. In an embodiment, the conduitincludes:

(i) an annular wall composed of a polymeric material, the annular walldefining an annular passageway;

(ii) a plurality of channels extending along a length of an innersurface of the annular wall; and

(iii) a slip material located in the channels, the slip material forminga capillary structure in the channels, and the capillary structuresprotruding radially inward from the annular wall.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conduit in accordance with anembodiment of the present disclosure.

FIG. 1A is a cross-sectional view of the conduit taken along line 1A-1Aof FIG. 1 in accordance with an embodiment of the present disclosure.

FIG. 2 is a perspective view of a conduit in accordance with anotherembodiment of the present disclosure.

FIG. 2A is a cross-sectional view of the conduit taken along line 2A-2Aof FIG. 2 in accordance with an embodiment of the present disclosure.

FIG. 3A is a cross-sectional view of a conduit in accordance with anembodiment of the present disclosure.

FIG. 3B is a cross-sectional view of a conduit in accordance withanother embodiment of the present disclosure.

FIG. 3C is a cross-sectional view of a conduit in accordance withanother embodiment of the present disclosure.

FIG. 3D is a cross-sectional view of a conduit in accordance withanother embodiment of the present disclosure.

FIG. 4 is a perspective cut-away view of a die assembly formanufacturing a conduit in accordance with an embodiment of the presentdisclosure.

FIG. 5 is a perspective view of a coated conductor within a conduit inaccordance with an embodiment of the present disclosure.

FIG. 5A is a cross-sectional view of the coated conductor within aconduit taken along line 5A-5A of FIG. 5 in accordance with anembodiment of the present disclosure.

DEFINITIONS AND TEST METHODS

Any reference to the Periodic Table of Elements is that as published byCRC Press, Inc., 1990-1991. Reference to a group of elements in thistable is by the new notation for numbering groups.

For purposes of United States patent practice, the contents of anyreferenced patent, patent application or publication are incorporated byreference in their entirety (or its equivalent US version is soincorporated by reference) especially with respect to the disclosure ofdefinitions (to the extent not inconsistent with any definitionsspecifically provided in this disclosure) and general knowledge in theart.

The numerical ranges disclosed herein include all values from, andincluding, the lower and upper value. For ranges containing explicitvalues (e.g., 1 or 2; or 3 to 5; or 6; or 7), any subrange between anytwo explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5to 6; etc.).

Unless stated to the contrary, implicit from the context, or customaryin the art, all parts and percents are based on weight and all testmethods are current as of the filing date of this disclosure.

Coefficient of Friction (COF) is measured according to ASTM D1894. Thesubstrate employed for COF determinations is DOW HDPE DGDB-2480 NT,which is a high-density polyethylene commercially available from The DowChemical Company, Midland, Mich., USA.

The term “composition” refers to a mixture of materials which comprisethe composition, as well as reaction products and decomposition productsformed from the materials of the composition.

The terms “comprising,” “including,” “having” and their derivatives, arenot intended to exclude the presence of any additional component, stepor procedure, whether or not the same is specifically disclosed. Inorder to avoid any doubt, all compositions claimed through use of theterm “comprising” may include any additional additive, adjuvant, orcompound, whether polymeric or otherwise, unless stated to the contrary.In contrast, the term “consisting essentially of” excludes from thescope of any succeeding recitation any other component, step, orprocedure, excepting those that are not essential to operability. Theterm “consisting of” excludes any component, step, or procedure notspecifically delineated or listed. The term “or,” unless statedotherwise, refers to the listed members individually as well as in anycombination. Use of the singular includes use of the plural and viceversa.

A “conductor” is one or more wire(s), or one or more fiber(s), forconducting heat, light, and/or electricity. The conductor may be asingle-wire/fiber or a multi-wire/fiber and may be in strand form or intubular form. Nonlimiting examples of suitable conductors include carbonand various metals, such as silver, gold, copper, and aluminum. Theconductor may also be optical fiber made from either glass or plastic.The conductor may or may not be disposed in a protective sheath. A“cable” is a conductor whereby two or more wires, or two or more opticalfibers, are bound together, optionally in a common insulation covering.The individual wires or fibers inside the covering may be bare, covered,or insulated. Combination cables may contain both electrical wires andoptical fibers. The cable can be designed for low, medium, and/or highvoltage applications. The cable may be a communication cable withoptical fiber, metal wire (such as copper wire), and combinationsthereof. Nonlimiting examples of cable designs are illustrated in U.S.Pat. Nos. 5,246,783; 6,496,629; and 6,714,707, each incorporated hereinby reference.

Density is measured in accordance with ASTM D792. The result is recordedin grams (g) per cubic centimeter (g/cc or g/cm³).

An “ethylene-based polymer” is a polymer that contains more than 50 molepercent polymerized ethylene monomer (based on the total amount ofpolymerizable monomers) and, optionally, may contain at least onecomonomer. Ethylene-based polymer includes ethylene homopolymer, andethylene copolymer (meaning units derived from ethylene and one or morecomonomers). The terms “ethylene-based polymer” and “polyethylene” maybe used interchangeably. Nonlimiting examples of ethylene-based polymer(polyethylene) include low density polyethylene (LDPE) and linearpolyethylene. Nonlimiting examples of linear polyethylene include linearlow density polyethylene (LLDPE), ultra low density polyethylene(ULDPE), very low density polyethylene (VLDPE), multi-componentethylene-based copolymer (EPE), ethylene/α-olefin multi-block copolymers(also known as olefin block copolymer (OBC)), single-site catalyzedlinear low density polyethylene (m-LLDPE), substantially linear, orlinear, plastomers/elastomers, medium density polyethylene (MDPE), andhigh density polyethylene (HDPE). Generally, polyethylene may beproduced in gas-phase, fluidized bed reactors, liquid phase slurryprocess reactors, or liquid phase solution process reactors, using aheterogeneous catalyst system, such as Ziegler-Natta catalyst, ahomogeneous catalyst system, comprising Group 4 transition metals andligand structures such as metallocene, non-metallocene metal-centered,heteroaryl, heterovalent aryloxyether, phosphinimine, and others.Combinations of heterogeneous and/or homogeneous catalysts also may beused in either single reactor or dual reactor configurations.

“Ethylene plastomers/elastomers” are substantially linear, or linear,ethylene/α-olefin copolymers containing homogeneous short-chainbranching distribution comprising units derived from ethylene and unitsderived from at least one C₃-C₁₀ α-olefin comonomer, or at least oneC₄-C₈ α-olefin comonomer, or at least one C₆-C₈ α-olefin comonomer.Ethylene plastomers/elastomers have a density from 0.870 g/cc, or 0.880g/cc, or 0.890 g/cc to 0.900 g/cc, or 0.902 g/cc, or 0.904 g/cc, or0.909 g/cc, or 0.910 g/cc, or 0.917 g/cc. Nonlimiting examples ofethylene plastomers/elastomers include AFFINITY™ plastomers andelastomers (available from The Dow Chemical Company), EXACT™ Plastomers(available from ExxonMobil Chemical), Tafmer™ (available from Mitsui),Nexlene™ (available from SK Chemicals Co.), and Lucene™ (available LGChem Ltd.).

“High density polyethylene” (or “HDPE”) is an ethylene homopolymer or anethylene/α-olefin copolymer with at least one C₄-C₁₀ α-olefin comonomer,or C₄ α-olefin comonomer and a density from greater than 0.94 g/cc, or0.945 g/cc, or 0.95 g/cc, or 0.955 g/cc to 0.96 g/cc, or 0.97 g/cc, or0.98 g/cc. The HDPE can be a monomodal copolymer or a multimodalcopolymer. A “monomodal ethylene copolymer” is an ethylene/C₄-C₁₀α-olefin copolymer that has one distinct peak in a gel permeationchromatography (GPC) showing the molecular weight distribution. Anonlimiting example of a suitable HDPE is CONTINUUM™ DGDA-2490 KB,available from The Dow Chemical Company.

A “jacket” is a coating on the conductor. The jacket may be in directcontact with the conductor. Alternatively, one or more interveninglayers may be present between the jacket and the conductor.

“Linear low density polyethylene” (or “LLDPE”) is a linearethylene/α-olefin copolymer containing heterogeneous short-chainbranching distribution comprising units derived from ethylene and unitsderived from at least one C₃-C₁₀ α-olefin comonomer or at least oneC₄-C₈ α-olefin comonomer, or at least one C₆-C₈ α-olefin comonomer.LLDPE is characterized by little, if any, long chain branching, incontrast to conventional LDPE. LLDPE has a density from 0.916 g/cc to0.925 g/cc. Nonlimiting examples of LLDPE include TUFLIN™ linear lowdensity polyethylene resins (available from The Dow Chemical Company),DOWLEX™ polyethylene resins (available from the Dow Chemical Company),and MARLEX™ polyethylene (available from Chevron Phillips).

“Low density polyethylene” (or “LDPE”) is an ethylene homopolymer, or anethylene/α-olefin copolymer comprising at least one C₃-C₁₀ α-olefin, ora C₃-C₄ α-olefin, that has a density from 0.915 g/cc to 0.925 g/cc andcontains long chain branching with broad molecular weight distribution(MWD). LDPE is typically produced by way of high pressure free radicalpolymerization (tubular reactor or autoclave with free radicalinitiator). Nonlimiting examples of LDPE include MarFlex™ (ChevronPhillips), LUPOLEN™ (LyondellBasell), as well as LDPE products fromBorealis, Ineos, ExxonMobil, and others.

“Medium density polyethylene” (or “MDPE”) is an ethylene homopolymer, oran ethylene/α-olefin copolymer comprising at least one C₃-C₁₀ α-olefin,or a C₃-C₄ α-olefin, that has a density from 0.926 g/cc to 0.940 g/cc.

Melt temperature, or “T_(m)” as used herein (also referred to as amelting peak in reference to the shape of the plotted DSC curve) istypically measured by the DSC (Differential Scanning calorimetry)technique for measuring the melting points or peaks of polyolefins, asdescribed in U.S. Pat. No. 5,783,638. It should be noted that manyblends comprising two or more polyolefins will have more than onemelting point or peak, many individual polyolefins will comprise onlyone melting point or peak.

“Multi-component ethylene-based copolymer” (or “EPE”) comprises unitsderived from ethylene and units derived from at least one C₃-C₁₀α-olefin comonomer, or at least one C₄-C₈ α-olefin comonomer, or atleast one C₆-C₈ α-olefin comonomer, such as described in patentreferences U.S. Pat. Nos. 6,111,023; 5,677,383; and 6,984,695. EPEresins have a density from 0.905 g/cc, or 0.908 g/cc, or 0.912 g/cc, or0.920 g/cc to 0.926 g/cc, or 0.929 g/cc, or 0.940 g/cc, or 0.962 g/cc.Nonlimiting examples of EPE resins include ELITE™ enhanced polyethylene(available from The Dow Chemical Company), ELITE AT™ advanced technologyresins (available from The Dow Chemical Company), SURPASS™ Polyethylene(PE) Resins (available from Nova Chemicals), and SMART™ (available fromSK Chemicals Co.).

A “multimodal ethylene copolymer” is an ethylene/C₄-C₁₀ α-olefincopolymer that has at least two distinct peaks in a GPC showing themolecular weight distribution. Multimodal includes copolymer having twopeaks (bimodal) as well as copolymer having more than two peaks.Nonlimiting examples of HDPE include DOW™ High Density Polyethylene(HDPE) Resins (available from The Dow Chemical Company), ELITE™ EnhancedPolyethylene Resins (available from The Dow Chemical Company),CONTINUUM™ Bimodal Polyethylene Resins (available from The Dow ChemicalCompany), LUPOLEN™ (available from LyondellBasell), as well as HDPEproducts from Borealis, Ineos, and ExxonMobil.

An “olefin-based polymer” or “polyolefin” is a polymer that containsmore than 50 mole percent polymerized olefin monomer (based on totalamount of polymerizable monomers), and optionally, may contain at leastone comonomer. Nonlimiting examples of olefin-based polymer includeethylene-based polymer and propylene-based polymer.

A “polymer” is a compound prepared by polymerizing monomers, whether ofthe same or a different type, that in polymerized form provide themultiple and/or repeating “units” or “mer units” that make up a polymer.The generic term polymer thus embraces the term homopolymer, usuallyemployed to refer to polymers prepared from only one type of monomer,and the term copolymer, usually employed to refer to polymers preparedfrom at least two types of monomers. It also embraces all forms ofcopolymer, e.g., random, block, etc. The terms “ethylene/α-olefinpolymer” and “propylene/α-olefin polymer” are indicative of copolymer asdescribed above prepared from polymerizing ethylene or propylenerespectively and one or more additional, polymerizable α-olefin monomer.It is noted that although a polymer is often referred to as being “madeof” one or more specified monomers, “based on” a specified monomer ormonomer type, “containing” a specified monomer content, or the like, inthis context the term “monomer” is understood to be referring to thepolymerized remnant of the specified monomer and not to theunpolymerized species. In general, polymers herein are referred to hasbeing based on “units” that are the polymerized form of a correspondingmonomer.

A “propylene-based polymer” is a polymer that contains more than 50 molepercent polymerized propylene monomer (based on the total amount ofpolymerizable monomers) and, optionally, may contain at least onecomonomer.

A “sheath” is a generic term and when used in relation to cables, itincludes insulation coverings or layers, protective jackets and thelike.

“Ultra low density polyethylene” (or “ULDPE”) and “very low densitypolyethylene” (or “VLDPE”) each is a linear ethylene/α-olefin copolymercontaining heterogeneous short-chain branching distribution comprisingunits derived from ethylene and units derived from at least one C₃-C₁₀α-olefin comonomer, or at least one C₄-C₈ α-olefin comonomer, or atleast one C₆-C₈ α-olefin comonomer. ULDPE and VLDPE each has a densityfrom 0.885 g/cc, or 0.90 g/cc to 0.915 g/cc. Nonlimiting examples ofULDPE and VLDPE include ATTANE™ ultra low density polyethylene resins(available form The Dow Chemical Company) and FLEXOMER™ very low densitypolyethylene resins (available from The Dow Chemical Company).

DETAILED DESCRIPTION

The present disclosure provides a conduit. In an embodiment, the conduitincludes an annular wall composed of a polymeric material, the annularwall defining an annular passageway. The conduit also includes aplurality of channels extending along a length of an inner surface ofthe annular wall, and a slip material located in the channels. The slipmaterial forms a capillary structure in the channels, and the capillarystructures protrude radially inward from the annular wall.

In an embodiment, a coated conductor is disposed in the conduit.

A “conduit,” as used herein, is an elongated tube-shaped structurehaving an annular wall. The annular wall defines an annular passagewayextending through the conduit. The annular wall may or may not be asingle-layer structure, or a multi-layer structure. FIG. 1 shows aconduit 60 with an annular wall 66 that defines an annular passageway61. An article, such as a coated conductor, may extend through, orotherwise be disposed within, the annular passageway 61. The annularwall 66 has opposing surfaces—an outer surface 64 and an inner surface62—as shown in FIG. 1.

The annular wall 66 is composed of a polymeric material. Nonlimitingexamples of suitable polymeric materials include polyolefins (such asethylene-based polymers and propylene-based polymers), polyvinylchloride (“PVC”), and combinations thereof. In an embodiment, thepolymeric material is an ethylene-based polymer, a propylene-basedpolymer, PVC, or combinations thereof.

In an embodiment, the polymeric material includes an ethylene-basedpolymer. Nonlimiting examples of suitable ethylene-based polymer(polyethylene) include low density polyethylene (LDPE) and linearpolyethylene. Nonlimiting examples of suitable linear polyethyleneinclude linear low density polyethylene (LLDPE), multi-componentethylene-based copolymer (EPE), ethylene/α-olefin multi-block copolymers(also known as olefin block copolymer (OBC)), single-site catalyzedlinear low density polyethylene (m-LLDPE), substantially linearpolyethylene, or linear polyethylene, ethylene-basedplastomers/elastomers, medium density polyethylene (MDPE), and highdensity polyethylene (HDPE) and combinations thereof.

In an embodiment, the polymeric material is MDPE.

In an embodiment, the polymeric material is HDPE.

In an embodiment, the polymeric material includes a propylene-basedpolymer. Nonlimiting examples of suitable propylene-based polymersinclude propylene homopolymers, random propylene copolymers, propyleneimpact copolymers, propylene/α-olefin copolymers and combinationsthereof.

In an embodiment, the polymeric material includes a propylenehomopolymer.

In another embodiment, the polymeric material includes apropylene/α-olefin copolymer. Suitable α-olefins include, but are notlimited to, C₄-C₂₀ α-olefins or C₄-C₁₀ α-olefins. Nonlimiting examplesof suitable α-olefins include 1-butene, 1-pentene, 1-hexene, 1-hepteneand 1-octene.

In an embodiment, the polymeric material includes polyvinyl chloride(“PVC”).

The polymeric material may or may not include an additive. Nonlimitingexamples of suitable additives include antioxidants, colorants, ultraviolet (UV) absorbers or stabilizers, anti-blocking agents, flameretardants, compatibilizers, plasticizers, fillers, processing aids,crosslinking agents (e.g., peroxides), and combinations thereof.

In an embodiment, the polymeric material includes an antioxidant.Nonlimiting examples of suitable antioxidants include phenolicantioxidants, thio-based antioxidants, phosphate-based antioxidants, andhydrazine-based metal deactivators. In a further embodiment, thepolymeric material includes an antioxidant, such as IRGANOX 1035,present in an amount from 0.1 wt %, or 0.2 wt % to 0.3 wt % based on thetotal weight of the polymeric material.

In an embodiment, the polymeric material includes a filler. Nonlimitingexamples of suitable fillers include zinc oxide, zinc borate, zincmolybdate, zinc sulfide, clays such as organo-clay, carbon black,calcium carbonate, glass fiber, and combinations thereof. The filler mayor may not have flame retardant properties.

In an embodiment, the polymeric material includes a processing aid.Nonlimiting examples of suitable processing aids include oils, organicacids (such as stearic acid), and metal salts of organic acids (such aszinc stearate).

The annular wall may comprise two or more embodiments disclosed herein.

1. Plurality of Channels

In FIG. 1, the conduit 10 includes a plurality of channels extendingalong a length, L, of the inner surface of the annular wall 66. Theconduit 60 has a plurality of channels 68 extending along the length, L,of the inner surface 62 of the annular wall 66. A “channel” is anelongated void in the polymeric material of the annular wall 66. Eachchannel 68 is a small groove in the polymeric material, the channelextending along the length, L, of the inner surface 62 of the annularwall 66. When the annular wall 66 is a multi-layer structure, the innersurface 62 of the annular wall 66 is the inner surface of the innermostlayer. The depth of the channels does not extend to the outer surface 64of the annular wall 66. Each channel 68 is formed from a channel wall 69that extends around the perimeter of the channel, from a cross-sectionalview, as shown in FIGS. 3A-3D. The channel wall 69 is formed from thepolymeric material that forms the annular wall 66.

Each channel 68 may extend along the entire length, L, of the innersurface 62 of the annular wall 66, or may extend along a portion of thelength, L, of the inner surface 62 of the annular wall 66. In anembodiment, each channel 68 extends along the entire, or substantiallythe entire, length, L, of the inner surface 62 of the annular wall 66.In another embodiment, each channel 68 extends along a portion of thelength L, of the inner surface 62 of the annular wall 66. In anembodiment, each channel 68 extends along from 50%, or 60%, or 70% to80%, or 90%, or 95%, or 99%, or 100% of the length, L, of the of theinner surface 62 of the annular wall 66. The channels 68 may extend thelength, L, of the inner surface 62 of the annular wall continuously orintermittently.

In an embodiment, the plurality of channels 68 extend along the length,L, of the inner surface 62 of the annular wall 66 in a pattern.Nonlimiting examples of suitable patterns include parallel, helical,sinusoidal and combinations thereof. In an embodiment, one or morechannels 68 may intersect, or otherwise contact one another. In afurther embodiment, the channels 68 intersect in a criss-cross pattern.

In an embodiment, the plurality of channels 68 extend along the length,L, of the inner surface 62 of the annular wall 66 in a parallel pattern.The term “parallel,” as used herein, refers to channels extending in thesame direction along the length, L, of the inner surface 62 of theannular wall 66, the channels maintaining a parallel orientation withrespect to longitudinal axis, X, as shown in FIG. 1. The parallelchannels to not intersect each other. FIGS. 1 and 1A depict parallelchannels 68.

In an embodiment, the plurality of channels 68 extend along the length,L, of the inner surface 62 of the annular wall 66 in a helical pattern.The term “helical,” as used herein, refers to channels extending in aspiral manner along the length, L, on and around the inner surface 62 ofthe annular wall 66, and not intersecting. FIGS. 2 and 2A depict helicalchannels 68.

In an embodiment, the plurality of channels 68 extend along the length,L, of the inner surface 62 of the annular wall 66 in a sinusoidalpattern (not shown). The term “sinusoidal,” as used herein, refers tochannels extending in a wave manner along the length, L, of the innersurface 62 of the annular wall 66. In a further embodiment, thesinusoidal pattern is composed of non-intersecting channels 68.

In an embodiment, one or more channels may intersect, or otherwisecontact, one another. In a further embodiment, the channels intersect ina criss-cross pattern.

The channels 68 are arranged in a spaced-apart manner along the innerannular wall 62. In an embodiment, the channels 68 are each spaced anequal distance from one another.

In an embodiment, the conduit 60 includes from 2, or 3, or 4, or 5, or 6to 7, or 8, or 9, or 10, or 11, or 12, or 13, or 14, or 15, or 16, or18, or 20, or 30, or 40, or 50 channels 68. In another embodiment, theconduit 60 includes from 2, or 4 to 8, or 10, or 15, or 20, or 30, or40, or 50 channels 68. In another embodiment, the conduit 60 includes atleast 2 channels 68.

The plurality of channels may comprise two or more embodiments disclosedherein.

2. Slip Material

A slip material is located in each of the channels. A “slip material” isa composition that has a low Coefficient of Friction (COF). A “lowCoefficient of Friction” is a COF of from 0.02 to 0.15. In anembodiment, the slip material has a COF of from 0.02, or 0.04, or 0.06,or 0.07, or 0.08, or 0.09, or 0.10 to 0.13, or 0.14, or 0.15.

Nonlimiting examples of suitable slip materials include silicone, fattyacid amides, plasticizers, organic amines, dibasic esters, stearates,sulfates, fatty acids, mineral oil, vegetable oils, fluorinated organicresins, graphite, tungsten disulfide, molybdenum disulfide, andcombinations thereof. The slip material may or may not also include apolymeric material. The polymeric material may be any polymeric materialdisclosed herein. In an embodiment, the polymeric material is anethylene-based polymer, a propylene-based polymer, a polyamide (such asnylon), or combinations thereof.

In an embodiment, the slip material is a silicone. A “silicone” is apolymer generally comprising siloxane-based monomer residue repeatingunits. A “siloxane” is a monomer residue repeat unit having theStructure (I):

wherein R¹ and R² each independently is hydrogen or a hydrocarbylmoiety. A “hydrocarbyl” is a univalent group formed by removing ahydrogen atom from a hydrocarbon (e.g., alkyl groups, such as ethyl, oraryl groups, such as phenyl). In an embodiment, the siloxane monomerresidue can be any dialkyl, diaryl, dialkaryl, or diaralkyl siloxane,having the same or differing alkyl, aryl, alkaryl, or aralkyl moieties.In an embodiment, each of R¹ and R² is independently a C₁ to C₂₀, or C₁to C₁₂, or C₁ to C₆ alkyl, aryl, alkaryl, or aralkyl moiety. In variousembodiments, R¹ and R² can have the same or a different number of carbonatoms. In various embodiments, the hydrocarbyl group for each of R¹ andR² is an alkyl group that is saturated and optionally straight-chain.Additionally, the alkyl group in such embodiments can be the same foreach of R¹ and R². Non-limiting examples of alkyl groups suitable foruse in R¹ and R² include methyl, ethyl, 1-propyl, 2-propyl, 1-butyl,isobutyl, t-butyl, or combinations of two or more thereof. Nonlimitingexamples of suitable silicone include polydimethylsiloxane (PDMS),poly(ethyl-methylsiloxane), and combinations thereof. Nonlimitingexamples of suitable silicone also include the silicones disclosed inInternational Publication No. WO 2014/172105, the disclosure of which isincorporated by reference herein in its entirety.

In an embodiment, the slip material is a fatty acid amide. A “fatty acidamide” is a molecule having the Structure (II):

wherein R is a C₃ to C₂₇ alkyl moiety. In an embodiment, R is a C₁₁ toC₂₅, or a C₁₅ to C₂₃ alkyl moiety. In another embodiment, R is a C₂₁alkyl moiety. R can be saturated, mono-unsaturated, or poly-unsaturated.In an embodiment, R is mono-unsaturated. Nonlimiting examples ofsuitable fatty acid amides include erucamide, oleamide, palmitamide,stearamide, and behenamide. Additionally, the fatty acid amide can be amixture of two or more fatty acid amides. In an embodiment, the fattyacid amide is erucamide. Nonlimiting examples of suitable fatty acidamides also include the fatty acid amides disclosed in InternationalPublication No. WO 2014/172105.

In an embodiment, the slip material is a stearate. Nonlimiting examplesof suitable stearates include zinc stearate, lead stearate, calciumstearate, and combinations thereof.

In an embodiment, the slip material is a sulfate. A nonlimiting exampleof a suitable sulfate is zinc sulfate.

In an embodiment, the slip material is a fatty acid. Nonlimitingexamples of suitable fatty acids include palmitic acid, stearic acid,and combinations thereof.

In an embodiment, the slip material is a fluorinated organic resin. A“fluorinated organic resin” is a polymer of one or more fluorinatedmonomers selected from tetrafloroethylene, vinylidene fluoride, andchlorotrifluoroethylene.

Nonlimiting examples of suitable commercially available slip materialsinclude MB50-314 (which is a 50:50 masterbatch of an ultra-highmolecular weight hydroxyl-terminated polydimethylsiloxane in an HDPEpolymer) and MB50-002 (which is a 50:50 masterbatch of an ultra-highmolecular weight siloxane polymer in a LDPE polymer), each availablefrom Dow Corning Corporation, Midland, Mich., USA.

In an embodiment, the slip material includes from 10%, or 20%, or 30% to40%, or 45%, or 50%, or 55%, or 60%, or 70%, or 75%, or 80%, or 90%, or100 wt % silicone, fatty acid amides, plasticizers, organic amines,dibasic esters, stearates, sulfates, fatty acids, mineral oil, vegetableoils, fluorinated organic resins, graphite, tungsten disulfide,molybdenum disulfide, or combinations thereof, based on the total weightof slip material. In another embodiment, the slip material includes from10%, or 20%, or 30% to 40%, or 45%, or 50%, or 55%, or 60%, or 70%, or75%, or 80%, or 90%, or 99 wt % silicone, fatty acid amides,plasticizers, organic amines, dibasic esters, stearates, sulfates, fattyacids, mineral oil, vegetable oils, fluorinated organic resins,graphite, tungsten disulfide, molybdenum disulfide, or combinationsthereof; and a reciprocal amount of a polymeric material, or from 1 wt%, or 10 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 40 wt %, or 54 wt%, or 50 wt %, or 55 wt %, or 60 wt % to 70 wt %, or 80 wt %, or 90 wt %polymeric material, based on the total weight of the slip material.

The slip material may or may not include additives. The additive may beany additive disclosed herein.

The slip material may comprise two or more embodiments disclosed herein.

3. Capillary Structure

The slip material forms a capillary structure in the channels. A“capillary structure” is a formation having a height, width, and depthand composed of the slip material. In other words, the capillarystructure is a three-dimensional structure. Each capillary structure 70protrudes radially inward from the annular wall 66, as shown in FIGS. 1,2 and 3A-3D. A capillary structure that “protrudes radially inward fromthe annular wall” has a portion that extends inward beyond the innersurface of the annular wall. Alternatively, one or more of the capillarystructures 70 may be co-extensive with the inner surface 62 of theannular wall 66.

The capillary structure 70 has a cross-sectional shape. Nonlimitingexamples of suitable cross-sectional shapes for the capillary structure70 includes an ellipse, a polygon, and combinations thereof.

In an embodiment, the capillary structure 70 has a polygoncross-sectional shape. A “polygon” is a closed-plane figure bounded byat least three sides. The polygon can be a regular polygon, or anirregular polygon having three, four, five, six, seven, eight, nine, tenor more sides. Nonlimiting examples of suitable polygonal shapes includetriangle, square, rectangle, diamond, trapezoid, parallelogram, hexagonand octagon. FIG. 3B depicts capillary structures 70 b that have atriangle cross-sectional shape. FIG. 3C depicts capillary structures 70c that have a trapezoid cross-sectional shape. FIG. 3D depicts capillarystructures 70 d that have a diamond cross-sectional shape.

In an embodiment, the capillary structure 70 has an ellipsecross-sectional shape. An “ellipse” is a plane curve such that the sumof the distances of each point in its periphery from two fixed points,the foci, are equal. The ellipse has a center which is the midpoint ofthe line segment linking the two foci. The ellipse has a major axis (thelongest diameter through the center). The minor axis is the shortestline through the center. The ellipse center is the intersection of themajor axis and the minor axis. A “circle” is a specific form of ellipse,where the two focal points are in the same place (at the circle'scenter). Nonlimiting examples of ellipse shapes include circle, oval,and ovoid. FIG. 3A depicts capillary structures 70 a that have a circlecross-sectional shape.

In an embodiment, the capillary structures 70 have a cross-sectionalshape that is a circle, a triangle, a trapezoid, a diamond, andcombinations thereof.

The channels 68 have a reciprocal cross-sectional shape compared to thecross-sectional shape of the capillary structures 70 (e.g., 70 a, 70 b,70 c, 70 d), as shown in FIGS. 3A-3D. A channel having a “reciprocalcross-sectional shape” to that of a capillary structure has aconfiguration adapted to receive a portion of the capillary structure.For example, a channel 68 a has a reciprocal cross-sectional shape thatis an arc that mates with the circle cross-sectional shape of thecapillary structure 70 a, as shown in FIG. 3A. In an embodiment, thecapillary structures 70 are anchored within the annular wall 66 suchthat the widest point of the cross-sectional shape of each capillarystructure 70 is positioned within the annular wall 66. FIGS. 3A-3D showcapillary structures 70 in which the widest point of the cross-sectionalshape of each capillary structure 70 is positioned within the annularwall 66.

Each capillary structure 70 extends along the length of a respectivechannel 68. In an embodiment, the capillary structures 70 extend alongall, or substantially all, of the length of the channels 68.

Each capillary structure 70 has a volume. The “volume” of a capillarystructure is equal to the area of the cross-sectional shape of thecapillary structure, multiplied by the length of the capillarystructure. In an embodiment, from 5%, or 10%, or 15%, or 20%, or 25% to30%, or 35%, or 40%, or 45%, or less than 50%, or 50% of the volume ofeach capillary structure 70 protrudes radially inward from the annularwall 66. In an embodiment, from 5%, or 10%, or 15%, or 20%, or 25% to30%, or 35%, or 40%, or 45%, or less than 50%, or 50% of the volume ofeach capillary structure 70 protrudes radially inward from the annularwall 66, and a reciprocal amount, or from 50%, or less than 50%, or 55%,or 60%, or 65%, or 70% to 75%, or 80%, or 85%, or 90%, or 95% of thevolume of each capillary structure 70 is positioned within the channel68 of the annular wall 66.

The number of capillary structures 70 equals, or otherwise correspondsto, the number of channels 68. In an embodiment, the conduit 60 includesfrom 2, or 3, or 4, or 5, or 6 to 7, or 8, or 9, or 10, or 11, or 12, or13, or 14, or 15, or 16, or 18, or 20, or 30, or 40, or 50 capillarystructures 70. In another embodiment, the conduit 60 includes from 2, or4 to 8, or 10, or 15, or 20, or 30, or 40, or 50 capillary structures70. In another embodiment, the conduit 60 includes at least 2 capillarystructures 70.

In an embodiment, each capillary structure 70 is adhered to a respectivechannel 68. Each capillary structure adheres to its respective channelby way of co-extrusion alone, or in combination with, the matedstructural pairing of the capillary structure cross-sectional shape tothe reciprocal cross-sectional shape of the channel.

In an embodiment, the annular wall 66 and the slip material areco-extruded, as discussed below.

In an embodiment, each capillary structure 70 formed from a slipmaterial is also coated with a slip material (hereinafter “slipcoating”). The slip coating may be any slip material disclosed herein.The slip coating may be the same material as the slip material, or adifferent material than the slip material.

The capillary structures may comprise two or more embodiments disclosedherein.

In an embodiment, the conduit 60 includes:

(i) an annular wall 66 composed of a polymeric material that is anethylene-based polymer (such as MDPE), a propylene-based polymer, PVC,or combinations thereof, the annular wall 66 defining an annularpassageway 61;

(ii) from 2, or 3, or 4, or 5, or 6 to 7, or 8, or 9, or 10, or 11, or12, or 13, or 14, or 15, or 16, or 18, or 20, or 30, or 40, or 50channels 68 extending along a length, L, of an inner surface 62 of theannular wall 66; and

(iii) a slip material that is a silicone, a fatty acid amide, aplasticizer, an organic amine, a dibasic ester, a stearate, a sulfate, afatty acid, a mineral oil, a vegetable oil, fluorinated organic resin,graphite, tungsten disulfide, molybdenum disulfide, or combinationsthereof, the slip material located in the channels 68 and forming acapillary structure 70 in the channels 68,

wherein the capillary structures 70 protrude radially inward from theannular wall 66. In an embodiment, the capillary structures 70 have across-sectional shape that is an ellipse, a polygon, or combinationsthereof. In another embodiment, from 5%, or 10%, or 15%, or 20%, or 25%to 30%, or 35%, or 40%, or 45%, or less than 50%, or 50% of the volumeof each capillary structure 70 protrudes radially inward from theannular wall 66. In an embodiment, the slip material also includes apolymeric material, such as an ethylene-based polymer (e.g., LDPE).

In an embodiment, the conduit 60 includes:

(i) an annular wall 66 composed of MDPE, the annular wall 66 defining anannular passageway 61;

(ii) from 2, or 4 to 8, or 10, or 15, or 20 channels 68 extending alonga length, L, of an inner surface 62 of the annular wall 66; and

(iii) a slip material containing a silicone and LDPE located in thechannels 68, the slip material forming a capillary structure 70 in thechannels 68, wherein the capillary structures 70 protrude radiallyinward from the annular wall 66. In an embodiment, the capillarystructures 70 have a cross-sectional shape that is a circle, a triangle,a trapezoid, a diamond, or combinations thereof. In another embodiment,from 5%, or 10%, or 15%, or 20%, or 25% to 30%, or 35%, or 40%, or 45%,or less than 50%, or 50% of the volume of each capillary structure 70protrudes radially inward from the annular wall 66.

In an embodiment, the conduit 60 has a thickness from 1 mm, or 2 mm to 3mm, or 5 mm, or 10 mm, or 15 mm, or 20 mm, or 25 mm, or 30 mm.

The conduit may comprise two or more embodiments disclosed herein.

In an embodiment, conduit 60 is produced via co-extrusion of thepolymeric material and the slip material using a spiral wound orcross-head mandrel assembly, such as the spiral wound mandrel assemblydepicted in FIG. 4. FIG. 4 depicts a mandrel assembly 100 provided withfeatures to facilitate the creation of channels in a conduit annularwall. The mandrel assembly 100 includes a housing 102, a cone-shaped tip106, a polymeric material inlet 112, and a slip material inlet 114. Thehousing 102 includes (i) a housing tubular channel 104 extending alongthe length of the housing, and the longitudinal centerline axis of thehousing 102; (ii) a fluid annular channel 116 encircling the housingtubular channel 104; and (iii) a fluid ring 118 in fluid communicationwith the fluid annular channel 116, the fluid ring 118 positioned at oneend of the housing. The cone-shaped tip 106 has a wide end 106 a and anarrow end 106 b. The wide end 106 a of the tip 106 is attached to theend of the housing 102 at which the fluid ring 118 is positioned. Thetip 106 includes a tip tubular channel 108 extending along the length ofthe tip 106 and the longitudinal centerline axis of the tip 106. The tip106 also includes a plurality of tip fluid channels 110, wherein eachtip fluid channel 110 is in fluid communication with the fluid ring 118.The tip 106 has a nozzle (not shown) in fluid communication with the tipfluid channels 110, the nozzle located at the end and extending beyondthe narrow end 106 b of the tip 106. The housing tubular channel 104 andthe tip tubular channel 108 are in open communication with one another.A polymeric material inlet 112 is in fluid communication with the fluidannular channel 116 such that polymeric material fed in to the mandrelassembly, depicted as Arrow A in FIG. 4, flows into the fluid annularchannel 116. The polymeric material flows through the fluid annularchannel 116 until it flows around the nozzle and forms an annular wall.The slip material inlet 114 is in fluid communication with the pluralityof tip fluid channels 110 such that slip material fed into the mandrelassembly, depicted as Arrow B in FIG. 4, flows into the tip fluidchannels 110. The slip material exits the tip fluid channels 110 throughthe nozzle into the polymeric material as the polymeric material formsthe annular wall 66. Because the nozzles extend beyond the end of thecone of the tip 106, the slip material from the nozzle enters thepolymeric material and as the polymeric material and slip materialsolidify, (i) forms channels in the annular wall and (ii) formscapillary structures from the slip material.

In an embodiment, the process for producing a coated conductor includes(i) heating the polymeric material to at least the melting temperatureof the polymeric material, (ii) heating the slip material to at leastthe melting temperature of the slip material, (iii) and thenco-extruding the polymeric material and the slip material to form anannular wall with channels, the channels containing capillary structuresformed from the slip material. The polymeric material and the slipmaterial each is in an extrudable state.

In an embodiment, the process for producing the present conduit utilizesthe process for producing a cable jacket as disclosed in U.S.Provisional Patent Application No. 62/427,358, filed 29 Nov. 2016, thedisclosure of which is incorporated by reference herein in its entirety.

4. Coated Conductor Disposed in a Conduit

In an embodiment, a coated conductor is disposed in the conduit. FIGS. 5and 5A depict a coated conductor 10 in the conduit 60.

In an embodiment, the coated conductor 10 includes a conductor 2 and acoating on the conductor. The coating is located on the conductor. Thecoating may wholly or partially cover or otherwise surround or encasethe conductor. The coating may be the sole component surrounding theconductor. Alternatively, the coating may be one layer of a multilayerjacket or sheath encasing the metal conductor. In an embodiment, thecoating directly contacts the conductor. In another embodiment, thecoating directly contacts an insulation layer surrounding the conductor.

In an embodiment, the coating is an outermost jacket 14 for a conductor.FIGS. 5 and 5A depict a coated conductor 10 with a jacket 14 for aconductor 2. The coated conductor 10 includes an insulation layer 16between the conductor 2 and the jacket 14. The jacket 14 directlycontacts the insulation layer 16, which surrounds the conductor 2.

The coating is formed from a polymeric material. The polymeric materialmay be any polymeric material previously disclosed herein.

In an embodiment, the coated conductor 10 includes a slip material onthe outer surface 12 of the coated conductor 10.

In an embodiment, the coated conductor is a coated conductor havingcapillary structures composed of slip material, the capillary structuresprotruding radially outward from the coating as disclosed in U.S.Provisional Patent Application Ser. No. 62/452,719, filed on 31 Jan.2017, the disclosure of which is incorporated by reference herein in itsentirety.

In an embodiment, the coated conductor includes:

a conductor; and

a coating on the conductor, the coating having:

-   -   (i) an annular wall composed of a polymeric material, the        annular wall surrounding at least a portion of the conductor;    -   (ii) a plurality of channels extending along a length of an        outer surface of the annular wall; and    -   (iii) a slip material located in the channels, the slip material        forming a capillary structure in the channels, and the capillary        structures protruding radially outward from the annular wall.

The polymeric material may be any polymeric material previouslydisclosed herein. The slip material may be any slip material previouslydisclosed herein.

In an embodiment, the coated conductor is a fiber optic cable, acommunications cable (such as a telephone cable or a local area network(LAN) cable), a power cable, wiring for consumer electronics, a powercharger wire for cell phones and/or computers, computer data cords,power cords, appliance wiring material, home interior wiring material,and consumer electronic accessory cords.

In an embodiment, at least one of the capillary structures 70 of theconduit 60 is in direct contact with the outer surface 12 of the coatedconductor 10. In another embodiment, at least two of the capillarystructures 70 of the conduit 60 are in direct contact with the outersurface 12 of the coated conductor 10. FIG. 5A depicts a coatedconductor 10 disposed in the conduit 60, wherein two of the capillarystructures 70 are in direct contact with the outer surface 12 of thecoated conductor 10.

The outer surface 12 of the coated conductor may or may not be incontact with the inner surface 62 of the conduit 60. In an embodiment,the outer surface 12 of the coated conductor 10 is not in contact withthe inner surface 62 of the conduit 60. The radially protrudingcapillary structures prevent the inner surface 62 of the conduit 60 fromcontacting the outer surface 12 of the coated conductor 10.

Bounded by no particular theory, it is believed that capillarystructures 70 formed from low COF slip material that protrude radiallyinward from the annular wall 66 reduce the tension that arises as acoated conductor 10 is pulled into and through a conduit 60. Thecapillary structures 70 reduce the surface area of the annular wall 66that comes into contact with the coated conductor 10. In this way, thelow COF slip material is in contact with the coated conductor. Tension,or friction, is reduced by (i) minimizing the contact surface areabetween the coated conductor and the conduit and (ii) the lubricatingeffect provided by the capillary structures made of low COF slipmaterial. Reduced tension, or friction, improves the ease ofinstallation of coated conductors, reduces the installation time ofcoated conductors through conduits, and results in less damage to coatedconductors and conduits during installation.

Bounded by no particular theory, it is also believed that formingcapillary structures 70 from low COF slip material uses a lower load ofslip material than comparative conduits in which (i) the slip materialis blended with the polymeric material to form the annular wall, and(ii) annular wall is coated, such as sprayed, with the slip material.Lower loads of low COF slip material are advantageous because low COFslip materials are expensive. Furthermore, capillary structures 70 thatare anchored within the annular wall 66 avoids the need for a tie layerto bond the polymeric material to the slip material.

The conduit may comprise two or more embodiments disclosed herein.

By way of example, and not limitation, examples of the presentdisclosure are provided.

Example

The conduit 60 of FIG. 1 is produced via co-extrusion using the mandrelassembly depicted in FIG. 4. The conduit 60 has an annular wall 66composed of a polymeric material that is a MDPE. The annular wall 66defines an annular passageway 61. Fifteen channels 68 extend along thelength of the inner surface 62 of the annular wall 66. The channels 68extend along the length of the inner surface 62 of the annular wall 66in a parallel pattern. A slip material that is MB50-002 (which is a50:50 masterbatch of an ultra-high molecular weight siloxane polymer ina LDPE polymer, available from Dow Corning Corporation, Midland, Mich.,USA) is co-extruded in the channels 68. The slip material formscapillary structures 70 in the channels 68. The capillary structures 70have a circle cross-sectional shape 70 a, as shown in FIGS. 1 and 3A.The capillary structures 70 protrude radially inward from the annularwall 66. From 5% to 50% of the volume of each capillary structure 70protrudes radially inward from the inner surface 62 of the annular wall66.

It is specifically intended that the present disclosure not be limitedto the embodiments and illustrations contained herein, but includemodified forms of those embodiments including portions of theembodiments and combinations of elements of different embodiments ascome within the scope of the following claims.

1. A conduit comprising: (i) an annular wall composed of a polymericmaterial, the annular wall defining an annular passageway; (ii) aplurality of channels extending along a length of an inner surface ofthe annular wall; and (iii) a slip material located in the channels, theslip material forming a capillary structure in the channels, and thecapillary structures protruding radially inward from the annular wall.2. The conduit of claim 1 wherein each capillary structure is adhered toa channel.
 3. The conduit of claim 1 wherein the annular wall and theslip material are co-extruded.
 4. The conduit of claim 1 wherein thechannels extend in a pattern along the length of the inner surface ofthe annular wall, the pattern selected from a parallel pattern, ahelical pattern, a sinusoidal pattern, or combinations thereof.
 5. Theconduit of claim 1 wherein each capillary structure has across-sectional shape selected from the group consisting of an ellipseand a polygon.
 6. The conduit of claim 1 wherein the conduit comprisesfrom 2 to 20 channels.
 7. The conduit of claim 1 wherein each capillarystructure has a volume, and from 5% to 50% of the volume of eachcapillary structure protrudes radially inward from the annular wall. 8.The conduit of claim 1 wherein the slip material is selected from thegroup consisting of a silicone, a fatty acid amide, a plasticizer, anorganic amine, a dibasic ester, a stearate, a sulfate, a fatty acid, amineral oil, a vegetable oil, and combinations thereof.
 9. The conduitof claim 1 wherein the slip material comprises a silicone.
 10. Theconduit of claim 8 wherein the slip material further comprises anethylene-based polymer.
 11. The conduit of claim 1 wherein the polymericmaterial is selected from the group consisting of an ethylene-basedpolymer, a propylene-based polymer, polyvinyl chloride (PVC), andcombinations thereof.
 12. The conduit of claim 1 wherein each capillarystructure has a volume, and from 5% to 50% of the volume of eachcapillary structure protrudes radially inward from the annular wall; andthe polymeric material comprises a medium density polyethylene (MDPE);and the slip material comprises a silicone and a low densitypolyethylene (LDPE).
 13. The conduit of claim 1, wherein a coatedconductor is disposed in the conduit.
 14. The conduit of claim 13wherein at least one of the capillary structures is in direct contactwith the coated conductor.
 15. The conduit of claim 1 wherein the coatedconductor comprises: a conductor; and a coating on the conductor, thecoating comprising (i) an annular wall composed of a polymeric material,the annular wall surrounding at least a portion of the conductor; (ii) aplurality of channels extending along a length of an outer surface ofthe annular wall; and (iii) a slip material located in the channels, theslip material forming a capillary structure in the channels, and thecapillary structures protruding radially outward from the annular wall.